Miniaturisation: Smaller Devices, Big Impact

Karl-Heinz, why is miniaturisation such an important topic in healthcare technology right now?

For some time now, there has been a clear market trend towards making medical devices smaller, lighter, and more multifunctional. Devices will not just do what they did in the past. For instance, hearing aids will become health monitors, measuring vital parameters like body temperature, heart rate and potentially even blood pressure. Applications like these need high performance in the smallest possible space.
 

What challenges do MedTech companies face in developing smaller devices?

One of the main challenges is that as designs become smaller and more complex, the manufacturing process becomes far more demanding. Many companies underestimate the value of involving manufacturing expertise early in the design phase – this is known as “Design for Manufacturing.” By doing so, we can help avoid design issues that are much harder to solve later in the project. Another challenge is that MedTech companies often struggle to build a supplier base that can meet all the technical requirements while also complying with the strict regulations of the medical field.
 

How can Cicor support customers in overcoming these challenges?

Cicor offers the complete chain from engineering through to production, including unique technologies such as Embedded PCB, DenciTec (Modified Semi-additive Process, mSAP), and Printed Electronics (Aerosol Jet Printing). For example, Embedded PCB technology allows us to integrate components directly into the PCB, saving space and improving performance – a key advantage for miniaturisation. Because we also handle assembly and testing, every step is optimised for size, functionality, and reliability. Our vertical integration means customers can move from concept to a qualified, manufacturable product without unnecessary handovers. Being able to work together with a single supplier that covers all required services brings huge benefits in terms of both quality and efficiency.
 

You mentioned Embedded PCB. What is it, and why is it relevant in MedTech?

An embedded PCB is a printed circuit board where certain components, such as integrated circuits, are placed directly inside the inner layers of the board instead of being mounted on the surface. This approach saves valuable space, reduces the profile of the device, and can improve performance by shortening interconnections and protecting components from mechanical or environmental stress. It also allows for better signal integrity and reduced energy consumption due to shorter connections.

In MedTech, this is particularly important because devices often need to be extremely small, lightweight, and discreet, for example in hearing aids. Embedded PCB also allows for better thermal management and can increase the durability of sensitive components, which is critical when devices are worn on or inside the body.
 

Cicor isn't the first to offer Embedded PCBs – what makes it stand out?

For example, one of the benefits we can offer is achieving pitch sizes and connection counts that are superior to most other available solutions. We also minimise component loss by embedding them only at the very end of the manufacturing process. It’s a challenging approach, but it ensures high yield and reliability. To make it work, we combine the capabilities of several Cicor sites, each contributing specific expertise. This is only possible because of Cicor’s unique combination of technological know-how and global footprint.

What role does Aerosol Jet Printing play in miniaturised medical devices?

Aerosol Jet Printing – we call it "Printed Electronics" – allows us to deposit very fine, precise layers of conductive or insulating materials directly onto a surface. This is particularly useful in miniaturised designs, where traditional manufacturing methods may not achieve the required resolution or flexibility.

In MedTech, this can mean adding fine interconnects, creating custom antenna structures, or applying selective insulation in areas that are difficult to reach with other techniques. It’s an additive process, so we only apply the material where it’s needed, which reduces waste and enables design features that would be impossible or too expensive with subtractive methods. By combining Aerosol Jet Printing with our other advanced processes, we can create compact, highly integrated assemblies that still meet the strict quality and reliability requirements of the medical sector.
 

Can you share an example where advanced PCB technology proved essential in a medical device?

A major medical company was developing a new catheter device for the examination and treatment of atrial fibrillation. Cicor was responsible for producing prototypes of the PCB needed for this device. The challenge was that standard PCB technology could not achieve the required resolution for the design.

We applied our mSAP (Modified Semi-Additive Process) technology, which offers extremely fine conductor structures, to successfully manufacture these circuits. This allowed us to meet the functional requirements within the limited space of the catheter while ensuring high reliability. The project is a good example of how advanced manufacturing processes can make the difference between a design that works in theory and one that can actually be produced to medical-grade standards.
 

To finish off – what do you enjoy most about working in miniaturisation?

The most exciting part for me is seeing how miniaturisation enables new therapies and treatments. Working with customers to find new and improved solutions is what motivates me most. These smaller, more advanced devices can improve quality of life for many people, and in some cases even help destigmatise devices and increase acceptance among users.

Also, I really appreciate working with people from different cultures and with expertise in many areas. Cicor’s set-up is unique, and it brings together skills covering almost the entire electronics manufacturing field, which creates opportunities to develop completely new devices.

Whether you’re developing a new device or scaling up for production, Cicor’s experts are here to support you every step of the way. With our integrated engineering and manufacturing capabilities, we help you bring innovative products to market faster and with fewer risks. Get in touch with us today to start the conversation. We’ll get back to you within 3 business days.